Apparatus and methods for secure, non-invasive and non-permanent surface attachment systems

ABSTRACT

A non-slip roof attachment system for attaching structures to residential and commercial roofs without the use of penetrations to roofing shingles and sealing layers is described. The non-slip attachment system may be used to attach roof mounted systems such as solar panels. The non-slip attachment system also allows for the quick removal of such roof mounted systems rapidly and without the need for repair of penetrations.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the United States ProvisionalApplication bearing the Ser. No. 62/387,325, filed Dec. 29, 2015. Thisapplication also claims the benefit of the United States ProvisionalApplication bearing the Ser. No. 62/387,326, filed Dec. 29, 2015. Thecontents of each are relied upon and hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to a surface mounted attachmentsystem and more specifically it relates to a roof mounted attachmentsystem for devices to a roof without a need to penetrate roof shinglesand underlying sealing layers or membranes.

BACKGROUND OF THE INVENTION

Increasingly, commercial and residential structures are being outfittedwith roof based structures such as solar photovoltaic or thermalinstallations which require fastening and support systems to securelyhold the roof based structure in place. In many cases theseinstallations are being utilized by homeowners and businesses in aneffort to reduce energy costs. Typically, such structures may be securedto a roof using devices such as an L-foot attachment, wherein thehorizontal portion of the L-foot is secured to structural elements onthe roof and the vertical portion is secured to the structure beingattached, such as solar panels or solar water collectors.

The methods used to install L-foot type attachments generallynecessitates penetration of the roof with a roof fastener such as ascrew in order to secure the L-foot attachment to the roof. In the past,various methods have been utilized to seal such a penetration to preventwater leakage into the roof. Such methods have included utilizingroofing sealant and flashing over the L-foot attachment. However,sealing penetration with roofing sealant may deteriorate over timeand/or crack. Utilizing flashing often requires that the flash itself benailed to the roof, which again creates new roof penetrations andpotential water leakage points. It would be desirable to have roofattachment systems which do not include portions which createpenetrations.

In a similar vein, the economic model for many of the roofinginstallations of structures used to generate energy have involvedownership of the structures by a third party. In cases where it isnecessary for the third part to remove a structure, the process may bevery involved when the support structures have utilized components whichpenetrate the roof. It may be expensive and time consuming to removesuch an energy generating structure once it has been installed. Hereto,it would be desirable to have systems that do not need to havepenetrations repaired and may be rapidly uninstalled.

Because of these inherent problems with the current related art, thereis a need for a new and improved roof attachment system that does notcreate penetrations to a roofing system.

SUMMARY OF THE INVENTION

Accordingly, methods and apparatus to attach roof structures withoutpenetrations are disclosed. Apparatus to be attached to roof structuresmay include, by way of non-limiting example a solar panel, a dishantenna, signage, water diversion members or other apparatus.

In some examples, a non-slip retainer attachment system for roofingstructures may be formed comprising roof shingles on a roof, wherein theroof shingles are arranged in a pattern with a seam between adjacentshingles, wherein the seam repeats in a vertical pattern from a base ofthe roof to the crest. The non-slip retainer attachment system may alsocomprise a device called an array stay, wherein the array stay includesa vertical member that protrudes through the seam between adjacentshingles and a lateral member that lies underneath one or both of theadjacent shingles and may be used as one of a plurality of array staymembers. The non-slip retainer attachment system may also comprise afirst hole in the vertical member of the array stay. The attachmentsystem may also include a first beam, wherein the first beam includes asecond hole, wherein a fastening component penetrates the first hole inthe vertical member and the second hole thereby attaching the first beamto the array stay.

In some examples, the non-slip retainer attachment system may includeexamples where the lateral member of the array stay is in the form of astraight bar. In other examples, the non-slip retainer attachment systemmay include examples wherein the lateral member of the array stay is inthe form of a spiral.

The non-slip retainer attachment system may also include high frictionpolymer foam padding, wherein the high friction polymer foam padding ispositioned between the first beam and the roof.

In some examples, a non-slip retainer attachment system may alsocomprise a second beam, wherein the second beam is positioned next tothe first beam, wherein the first beam and the second beam lie on distalsides of the of the vertical member of the array stay. In some of theseexamples, a non-slip retainer attachment system may also includeexamples where the first beam and the second beam include a verticalcomponent and a lateral component, wherein the first beam and the secondinclude pre-drilled holes, wherein the holes on the vertical componentof the first beam and the second beam are aligned.

In some examples, a non-slip retainer attachment system may furtherinclude a conventional solar panel slotted-rail attachment clips. Theattachment system may also include a first solar panel. In someexamples, the attachment system with an attached first solar panel mayalso include soffit under-mount hardware. The soffit under-mounthardware may also include one or more of a security camera, a motiondetector, an external lighting system, and an external speaker system,attached to the soffit under-mount hardware.

In some examples, a non-slip retainer attachment system may includemultiple quartz shingles with a solar power collection surface.

Implementations may include a method of reversibly attaching items to aroofing system. The method may comprise placing a first array-stayretainer attachment upon a roof, wherein a lateral member of the firstarray-stay retainer attachment is positioned underneath at least a firstroofing shingle and a vertical member of the first array-stay retainerattachment protrudes through a seam between the first roofing shingleand a second roofing shingle, and wherein the seam lies between an edgeof the first roofing shingle and an edge of the second roofing shingle.The method may also include placing a second array-stay retainerattachment upon a roof, wherein a lateral member of the secondarray-stay retainer attachment is positioned underneath at least a thirdroofing shingle and a vertical member of the second array-stay retainerattachment protrudes through a seam between the third roofing shingleand a fourth roofing shingle, and wherein the seam lies between an edgeof the third roofing shingle and an edge of the fourth roofing shingle.The method may also include placing a first half split-beam upon theroof, wherein the first half split-beam has pre-drilled holes, andwherein the first half split-beam pre-drilled holes align with a hole inthe first array stay retainer attachment and with a hole in the secondarray stay retainer attachment. The method may also include placing afastener into the hole in the first array stay retainer attachment andthrough a hole in the first half split-beam. The method may also includeattaching a slotted-rail attachment clip to at least the first halfsplit-beam. The method may also include attaching a support member tothe slotted rail attachment clip.

In some examples, the method may include examples where the lateralmember of the array stay is in the form of a straight bar. In someexamples, the method may include examples where the lateral member ofthe array stay is in the form of a spiral.

In some examples, the method may include examples which also includeattaching a solar panel to the support member. In some examples, themethod may include examples which also include removing the solar paneland removing the first array stay retainer attachment. In theseexamples, the roof under the first array stay does not have anypenetrations exposed after the removing of the first array stay retainerattachment. In some of these examples the method further includesrouting an electrical wire through a conduit from the solar panel alongthe support member. In some of these examples the method furtherincludes attaching a soffit under-mount hardware assembly to at leastthe first half split-beam, and attaching one or more of a securitycamera, a motion detector, an external lighting system, and an externalspeaker system, attached to the soffit under-mount hardware. In someexamples the first half split-beam may be rectangular in shape. In otherexamples the first half split-beam may be essentially oval in shape, andin still further examples the first half split-beam may be irregular inshape.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, that are incorporated in and constitute apart of this specification, illustrate several examples of the inventionand, together with the description, serve to explain the principles ofthe invention:

FIG. 1 illustrates an exemplary view of a roof rack system according tosome implementations of the present invention.

FIGS. 2A-2F illustrate components that may be included in an exemplaryarray-stay split-beam system with angled array-stays

FIGS. 3A-3C illustrate an exemplary array-stay beam system with blockform ballast and array-stays.

FIG. 4 illustrates a support channel with block form ballast andarray-stays.

FIGS. 5A and 5B illustrate a panel supported by block form stays withmodified angle array-stay.

FIGS. 6A-6D illustrate attachment aspects for exemplary spiral typestays.

FIG. 7 illustrates an exemplary under soffit support system that may beused in conjunction with an attached roof top array-stay split-beamsystem.

DETAILED DESCRIPTION OF PREFERRED EXAMPLES

The present invention provides apparatus, devices and methods toremovably attach equipment to tiled surfaces, such as a roof top withoutthe need to penetrate the surface of the roof and thereby compromise theintegrity of the roof. Items to be attached may include, for example, asolar panel, a dish antenna, a landing pad for a drone, signage, waterdiversion members or other apparatus. In some embodiments, the removableattachment provides for the attachment of equipment in a manner thatdoes not result in the equipment becoming a permanent part of thestructure to which the equipment is attached.

Referring to FIG. 1, a system of a roof rack system based on non-slipretainer attachments according some implementations of the presentinvention is illustrated. In some examples a roof rack system 100 mayinclude a roof peak cover 110, to protect from elements such as dust andice. The system may also include a roof racking system 120. In someexamples of the present invention, the roof racking system may providean easily removable, non-penetrating support system for roof mountedsystems such as solar array panels. In additional examples, a gutterbridge 130 may connect the roof racking system 120 to stabilizingfeatures that may connect under the soffit of a house.

Support members 140 may connect through a gutter bridge and providemounting support for various house systems that would otherwise need tobe affixed to the house. Some of the components, such as the roofracking system 120 may be installed as standalone structures, but whenthe structures in FIG. 1 are deployed from a first soffit on one side ofthe roof over the roof peak and back down the roof to a second soffitself-stabilizing structure may be formed which may have numerousfeatures to adjust and control tension on system elements betweenvarious points.

Tiled surfaces may include asphalt roofing tiles, ceramic tiles, ceramictiles, shake tiles or other types of tiles. It is also understood thatalthough the disclosure is generally written in view of a roof surface,other surfaces may also be used, such as building siding.

Array Stay—Split-Beam System

Referring to FIG. 2A, an example of an array-stay split-beam system 200is illustrated. The array stay system 200 as disclosed herein may beused in various implementations in conjunction with, or without, aballast. In addition, to the array-stay systems 200 depicted in FIG. 2Amay be utilized to non-invasively removably affix items upon a roof-top.Items to be affixed to the roof top may include by way of non-limitingexample, include, a solar panel, a dish antenna, signage, waterdiversion members or other apparatus. These systems provide means tosupport solar panel systems or other roof mounted devices without theneed to penetrate existing shingle roofing in the larger field of theroofing area. The fact that the support systems do not penetrate theroof creates further advantages such as easier removability of roofmounted systems and less repair needs required after removal of thearray-stay systems.

The array-stay split-beam system may include an asphalt shingle roofanchoring device/method that may allow anchoring to a shingle roofwithout penetrating the actual roofing. The array-stays 210 consist of90 degree aluminum angles which slip under the sides of shingles. Insome examples, the array-stays 210 may measure about one and a half inchwide. Again, the array stays may be inserted through the side and undera typical roofing shingle tab. The lateral leg 211 of each 90 degreeangle may extend under the shingle tab at least four inches. Thevertical leg 212 of the angles may extend approximately two inches. Inthis example, the array stay angles or clips may be inserted through thesides of two shingle tabs in opposite directions (left and right). Thetwo clips or angles may then be slid until they are in-line back to back202, with the two vertical legs touching each other, and towards theupper part of the shingles. Combinations of these two juxtaposed arraystays are inserted in every other row of shingles in a straight linewith the double array-stays about ten inches apart.

A split-beam 220 may consist of two 90 degree aluminum angles which arehalf split-beams 221, 222, with each leg of the angle at least twoinches wide in some examples. Once the array-stay clips 202 are inposition, the two halves of the split-beam 221, 222 may be placed oneither side of the row of array-stay clips 202, clamped together, andscrewed together with a stainless steel self-tapping screw 230,fastening the two halves of the split-beam 221, 222 together and to botharray-stay clips 202 at the same time at each array-stay 210 location(about ten inches apart). After all of the connections may be made, theeffect is that the split-beam 220 may be secured to the shingle roofwith multiple connection points to the features residing under theactual shingle roofing. The lateral legs of the split-beam 220 pressingdown on top of the shingle adds to the strength of the multipleunder-single connections. The split-beam 220 bottoms may have highfriction polymer foam padding 223 for adhesion and protection of thesurface.

Once the array-stays 210 and split-beam 220 angles are connected, amiddle slot may be formed between the split-beam 220 that may allow theinsertion of split-beam brackets 240. In an example the split-beambrackets 240 may consist of two inch by two inch aluminum angles (atleast one and a half inches long) that may fit into the slot to formconnection points for conventional solar panel slotted-rail attachmentclips. The two split-beam brackets 240 are attached to the split-beam220 with one stainless steel self-tapping screw 230. The conventionalslotted-rail attachment clips may be screwed to the split-beam railclips using the same screws 230.

There may be numerous components that make up and attach to thearray-stay split-beam system. Referring to FIG. 2B, array-stays areshown in isolation. As mentioned earlier a typical array stay mayinclude a vertical piece 212 and a lateral piece 201. Referring to FIG.2C the two sides of the split-beam are illustrated. A first halfsplit-beam 221 and a second half split-beam 222 are shown separated fromeach other. An exemplary high friction polymer foam padding 223 foradhesion and protection of the surface is also illustrated. Thesplit-beam halves may have pre drilled holes in them for easy use in thefield. Exemplary pre drilled holes are illustrated with holes in thelateral piece 270 and with holes in the vertical piece 280. These holesmay allow for other components to be screwed into the support system.Referring to FIG. 2D, an example of hardware that may be attached to thepre-drilled holes is illustrated. Conventional solar panel slotted-railattachment clips 250 are illustrated. Referring to FIG. 2E, anotherexample of hardware that may be attached to the split-beam components isillustrated. Split-beam brackets 240 may be assembled into the slotbetween split-beam components. Referring to FIG. 2F, an exemplary beam260 which may support solar panels is illustrated. This beam may beattached to the array-stay support system with the components such asillustrated in FIG. 2E and FIG. 2D in some examples.

In some embodiments, an array of solar power collecting glass shinglesmay be installed over an existing asphalt tile roof or other type tilingsurface. In such embodiments, the solar collecting device may include aglass or quartz tile with a solar collecting surface.

Ballast Array-Stay System

In some examples, the components of an array-stay system may besupplemented with components that may act as ballast weight to addpressure above the array stay anchor locations and to increase thesurface area attached to the array-stay system that interacts with theroof system. Referring to FIG. 3A, an exemplary array stay anchor 310configured to support ballast components is illustrated. The exemplaryarray stay anchor 310 may be fundamentally the same as mentionedpreviously with the exception that the top portion may be indented tosupport bending over the ballast piece. Referring to FIG. 3B a stackedillustration of the components are illustrated. A ballast piece 320 witha hole 321 in it lies above a frictional support pad 322 also with ahole in it. An array-stay can have the components stacked up the staybefore the top portion of the array stay is folded over the ballastpiece. In FIG. 3C, the array stay is illustrated with the top portionbent over 340.

Continuing to FIG. 4, a ballast array-stay system is illustrated. Theballast pieces 320 may be affixed to an array stay in a position thatallows a ballast piece to overlap a support bracket 410.

Referring to FIG. 5A a component related to ballast systems isillustrated. In some examples, a sleeve 510 may be utilized to insulatea stay from a ballast. In another aspect the sleeve 510 may be usedprotect a ballast material and array stay from abrasion with each other.As illustrated in FIG. 5B, large ballast pieces 530 may be laid outwithin a frame on a roof with a support frame held in place with theballast supported array stay components 520. A resulting supported framemay be used to support roof located components like solar panels.

Although the drawings generally illustrate rectangular and/or linearshapes of devices, it is noted that devices with circular, arcuate andirregular shapes may also be affixed to a roof with the current systems.In addition, solar shingles may be attached to a roof with existingshingles already intact without violating the integrity of the existingsurface.

Array-Stay Support Systems with Spiral Stay Designs

Referring to FIGS. 6A-6D, aspects of array-stay split-beam anchoringsystems using a spiral stay 600 are seen. As illustrated in FIG. 6A aspirally cut piece of sheet metal 610 may have folding points 611. Whenthe sheet metal is folded on the folding points 611 an array stay pieceas illustrated in FIG. 6B may be formed. The spiral array-stay may beanother type of anchoring device which may be used with asphalt roofshingles while not penetrating them or the underlying roof withanchoring hardware.

Referring to FIG. 6B, the spiral stay 600 is a thin, stiff, metal devicewith a square vertical leg that may be doubled over for added strengthand a circular spiral lateral leg that may extend from the vertical legin almost a full circle or spiral. The spiral-stay 600 may be made ofone piece and bent in two places to create the vertical leg 621 andlateral leg or spiral leg 622. The vertical leg of the stay may have apilot hole 631 to aid in screw attaching the split-beam halves to thespiral stay upright leg 621. The spiral leg 622 may be inserted under ashingle tab from the side of the shingle tab and the whole device may beturned using the upright leg further and further under the shingle untilit makes a full circle.

Referring to FIG. 6C, the dotted lines of item 630 illustrate how aspiral shaped piece may be rotated underneath the ceiling shingle. Wheninstalled by rotating the stay under the shingle, only the upright leg621 may be showing, emerging from between two adjacent roofing shingles.As shown in FIG. 6C, in some examples, when that the stay is rotated itmay surround a nailed region 632 of an adjacent roofing shingle;thereby, adding some additional holding force.

Referring to FIG. 6D, the spiral array stay is illustrated aligned witha support leg 640 which also may have pre-drilled holes as mentionedwith respect to earlier figures. The pre-drilled holes may be used tofasten the array stay 641 to the support leg 640. The support leg mayform part of the roofing support structure which may support a roofmounted solar panel system for example.

Removal of Array-Stay Systems

The above mentioned examples depict two basic exemplary types of arraystay components. Each of the types, the straight leg array stay and thespiral shaped array stay may be used to fasten a roof support system inplace in a manner that is not relatively permanent as would be the casefor supports that are bolted or nailed in place. This may mean thatremoval of a roof support system and what it is supporting may berelatively straight forward. And, there may be relatively little if anyroofing damage that may need to be repaired after the aforementionedremoval. To remove a straight leg array stay after all supportedstructure and supports are disconnected from the array stays, a workermay withdraw the array stay from its position under the roofing shingleby pulling it out, or by gently lifting the roofing shingle beforepulling out the array stay.

To remove the spiral-shaped stay during disassembly, the turningprocedure may be reversed after removing the split-beam halves until theentire device is cut from under the shingles. Since the spiral stay mustbe strong as well as thin to fit under the shingles, in some examples astainless steel may be a good material for this application. In someother examples other metals like aluminum or strong plastic materials orcomposite materials such as carbon fiber epoxy material may be used. Fordifferent types of materials the spiral-shaped stay may be painted oranodized to provide greater weather resistance, as well as to enhanceits appearance. A specific color, such as blue-gray, might be selectedin a standard or customized color. In some examples, a soap gel orliquid may be used as a lubricant to aid in inserting the spiral legunder the shingles, which may be washed away thoroughly after insertionto establish a frictional fit. In some examples, the tip or end of thespiral leg or the straight leg may be folded over to lessen thesharpness of the tip for easier insertion under the shingles.

Under Soffit Support Structures

Referring to FIG. 7, the roof mounted support structure may be made toextend under the soffits on either or both sides of the roof. In someexamples, such an extension under the soffits may allow for the systemto be more rigidly held to the houses main structure as support beamswrap around gutters and eaves and under soffits of roofs. Various pointsfrom the peak of the roof, through structures along the roof top and tosystems under the roof edge and soffit may have adjustment aspects thatallow for tensioning of the various components amongst themselves toafford a structure that sits as planar and straight as possible to theroof surface and the lines of the asphalt shingles. In conditions ofwind and other conditions that may exert stress upon the support system,a properly tensioned roof support system may increase the capabilitiesof the system as a whole. The structure that results under the soffitsmay have additional utility in some examples.

There may be numerous useful items that are typically affixed to ahouse's frame for external mounting under or near a soffit that may bemounted instead to the under roof structure of the array-stay supportsystem. In FIG. 7, an array-stay held support 710 may connect atconnector 715 to a support member which wraps around the edge of theroof and associated components such as gutter systems. The wrap aroundsupport member 720 may then be attached to a vertical support rail 730,which may connect to numerous wrap around supports to allow it tosupport weighted objects under the soffit. In some examples, securitycameras 740, exterior lighting systems 750, motion detectors 760, andexternal speakers or sound systems 770 may be mounted. There may benumerous other types of systems that may also be mounted on the undersoffit support system.

To install the various components of the array stay system includingarray stays, non-slip retainer, split-beams, and various attachmentcomponents, there may be components such as vertical roof tensionsupport beams of designated sizes which may be laid on the roof byworkers. A roof peak tensioner device may then be utilized. The variouscomponents may be initially connected loosely, with no applied tension.A worker may then connect the fascia/gutter bridge while the componentsare still loosely connected, and then proceed to attach the soffitunder-mount hardware. In some examples, there may be no componentssupported under the soffit. With these necessary components connected,and optional components connected, as desired, workers may proceed toadjust the tension, up or down as needed, to begin the process oftightening the precision brackets. The adjustment process may berepeated numerous times to balance the roofing structure in as ideal acondition as possible. As well, to maintain full connection to theopposing side soffit, fascia or gutter of the home or office, thestructure may be thought of as a single system with numerous componentsthat interact with each other and must be balanced between them. Anoptional terminator bar may have similar background tension devices. Thehorizontal module rack may be mostly made up of standard size piecesthat are specially engineered to fit the vertical beams of an array-staysystem. After the vertical tension and adjustment is finalized, workersmay install a roof peak dust/ice cover. Depending on the use of thearray stay structure, workers may install solar modules, flood lights,motion detection devices, cameras, or other related security hardwarealong with custom structures to route power connections, andvideo/audio/motion cabling or fiber optic around the various structures.

Glossary

Array-Stay: as used herein “array-stay” or “array stay” means acomponent comprising a vertical member and a lateral member, wherein thevertical member may fit in a seam between as installed roofing shingles.When the “array-stay” is in a mounted position at least a portion of thelateral member is positioned between a roofing shingle and anyunderlying roofing shingles as well as the roof. The array-stay may havesurface texture or other modifications to increase friction between itslateral member and the overlying roofing shingle.

While the disclosure has been described in conjunction with specificexamples, it is evident that many alternatives, modifications andvariations will be apparent to those skilled in the art in light of theforegoing description. Accordingly, this description is intended toembrace all such alternatives, modifications and variations as fallwithin its spirit and scope.

What is claimed is:
 1. A method of reversibly attaching items to aroofing system, the method comprising: placing a first circular coiledarray-stay retainer attachment upon a roof, wherein a lateral member ofthe first array-stay retainer attachment is positioned underneath atleast a first installed roofing shingle and a second installed roofingshingle, and a vertical member of the first array-stay retainerattachment protrudes through a seam between the first roofing shingleand the second roofing shingle, and wherein the seam lies between anedge of the first roofing shingle and an edge of the second roofingshingle and said vertical member; placing a second circular coiledarray-stay retainer attachment upon the roof, wherein a lateral memberof the second array-stay retainer attachment is positioned underneath atleast a third roofing shingle and a vertical member of the secondarray-stay retainer attachment protrudes through a seam between thethird roofing shingle and a fourth roofing shingle, and wherein the seamlies between an edge of the third roofing shingle and an edge of thefourth roofing shingle; placing a first half split-beam upon the roof,wherein the first half split-beam has a first pre-drilled hole, andwherein the first pre-drilled hole aligns with a hole in the first arraystay retainer attachment; placing a second half split-beam upon the roofsubstantially parallel with the first half split-beam, wherein thesecond half split-beam has a second pre-drilled hole, and wherein thesecond pre-drilled hole aligns with a hole in the second array stayretainer attachment; placing a fastener into the hole in the first arraystay retainer attachment and the hole in the first half split-beam;attaching a slotted-rail attachment clip to at least the first halfsplit-beam; and attaching a support member to the slotted railattachment clip.
 2. The method of claim 1 further comprising attaching asolar panel to the support member.
 3. The method of claim 2 furthercomprising: removing the solar panel; removing the first array stayretainer attachment; and wherein the roof under the first array staydoes not have any penetrations exposed after the removing of the firstarray stay retainer attachment.
 4. The method of claim 2 furthercomprising: attaching a soffit under-mount hardware assembly to at leastthe first half split-beam; and attaching one or more of a securitycamera, a motion detector, an external lighting system, and an externalspeaker system, attached to the soffit under-mount hardware.
 5. Themethod of claim 1, wherein the half split-beam is essentiallyrectangular in shape.
 6. The method of claim 1, wherein the halfsplit-beam is essentially oval in shape.
 7. The method of claim 1,wherein the half split-beam is irregular in shape.